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Monday, March 5, 2018

Thermoplastic Polyolefin Skin Instrument Panel


The use of TPO skin was recognized in the industry in 1999, when GM won the SPE® Most Innovative Use of Plastics Award in the Body Interior category. It improved safety by enabling air bag deployments, and reduced windshield fogging with the reduction of VOCs and odors without plasticizers and toxic stabilizers. The environmentally friendly all polyolefin system also enabled closed loop recycling and the replacement of PVC while reducing mass 10%. The TPO skin also improved interior quality by preventing brittle cracking, color fading (UV protection is improved by 4 times) and warping. Overall esthetics were improved by the dry haptic leather-like feel inherent in TPO skin.


OEM/Vehicle
General Motors
2000 Pontiac Bonneville
System Supplier
Inteva Products LLC
(Delphi Interior Systems)
Material Processor
   Inteva Products LLC
(Delphi Interior Systems)
Material Supplier
Mytex Polymers
Resin
TPO


For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Current-Projects/End-of-Life-Vehicle-Recycling.html?css=print

Volt Battery Impact Shield


This low cost, simple crash barrier protection shield boasts rapid development and implementation with innovative materials and molding. Six parts were molded together as one mold, requiring calculating the materials reaction when secondary waterjet cuts out each piece. Three composite material constructions were tested (polypropylene with 40%, 50% then 60% glass) while tooling and 12 sets of prototype parts were developed over a 6 week period. A test vehicle was crashed, with production intent parts, passing all
test criteria the following week. Production tooling and fixtures were also completed during that time (week 7). Full production was initiated in week 12. A 75% mass and 60% cost saving vs traditional high strength steel stamping with metal fabrication was achieved.

OEM/Vehicle
General Motors
2017 Buick Enclave
System Supplier
CSP Teijin
Material Processor
   CSP Teijin
Material Supplier
Quadrant Plastic Composites
Resin
GMTex X103F61-4/1-0/90° PP
Tooling/Equipment Supplier
Laval Tool and Mould

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Connectors.html?css=print

Energy Absorbing Collapsible Glove Box Bin


This bin, that holds and stores the owner's manual, collapses during impact to prevent severe femur loads while providing a beautiful flocked appearance. The new design provides a 400 gram weight savings while lowering femur loads from unacceptable to 5-star compliant. The support structure is injection molded with a
compressed PET internal shell. This 100% recyclable, patent pending, concept can be used on any vehicle line to address high femur load issues and assist in achieving a 5-star crash rating.


OEM/Vehicle
Ford Motor Company
2018 Ford Expedition
System Supplier
Detroit Manufacturing Systems
Material Processor
   Detroit Manufacturing Systems
Material Supplier
Advanced Composites
Resin
Basell - SG702 PP
Tooling/Equipment Supplier
Lamko Tool & Mold

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Switches-Sockets.html?css=print

Gen-3 4-way Head Restraint


This low cost, low mass, head restraint provides exceptional rigidity for whiplash protection. Its flexible design allows the front surface of the head restraint to be translated closer to or further from the occupant by 60 mm without incurred costs (allowing for the precise balancing of comfort and safety). Using plastic, in place of steel, as the primary load bearing component is new to front row head restraints. The part design eliminates manufacturing complexity making use of intelligent geometries so that readily available materials could be used. A $10.73 Million savings ($2.80/vehicle) is projected by the end of MY2020.


OEM/Vehicle
Ford Motor Company
2018 Ford F150
System Supplier
Windsor Machine and Stamping
Material Processor
   Windsor Machine and Stamping
Material Supplier
Ravago
Resin
Hylon N1000STHL PA
Tooling/Equipment Supplier
Integrity Tool & Mold

For More Information See: http://www.plastics-car.com/roadmapsummary

All Plastic Hood Leveler


This industry first all plastic hood leveler helps to manage pedestrian hood/ head impact to reduce head trauma. It features a light weight design, OEM snap-in quick assembly, preset and adjustable height, and is recyclable. A 50% weight savings and a 35% cost savings is estimated compared to current steel/plastic/rubber hood levelers. The snap-in base is Acetal for a strong snap feature and no squeak against the Nylon post. The threaded post is nylon for strength and low moisture dimensional influence. The over-molded bumper is TPE for no squeak on the inner hood and additional energy management. The interaction of the three chosen polymers allow for required use of their individual properties and also the collaborative energy management response as they work together to help reduce head impact trauma from beneath the hood inner upon a low speed pedestrian contact.

OEM/Vehicle
Ford Motor Company
2018 Lincoln Navigator
System Supplier
MacLean-Fogg, Engineered Plastic
Components, Inc.
Material Processor
   MacLean-Fogg, Engineered Plastic
Components, Inc
Material Supplier
DuPont Automotive, ExxonMobil
Resin
Zytel 70G33 PA66, Delrin 100 POM,
Santoprene SA60 TPE
Tooling/Equipment Supplier
Elite Tool & Die

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Automobile-Designs-of-the-Future?css=print

D Pillar


This is an Industry-first use of a polycarbonate copolymer material on a D Pillar. Improved impact performance vs. PMMA was achieved and it allowed for rivet attachment to the vehicle without failure during environmental testing. The material demonstrated good UV, heat, and gloss performance. The material change also made it possible to achieve a high gloss piano black mold-in-color to OEM standards.

OEM/Vehicle
Ford Motor Company
2018 Ford Expedition
System Supplier
Windsor Mold Group
Material Processor
   AUTOPLAS
Material Supplier
SABIC
Resin
LEXAN SLX 2271T PC Copolymer
Tooling/Equipment Supplier
Windsor Mold Group

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles?css=print

Paint Racks with Robber Bars for Electrostatic Paint Line



This painting process uses racks with “Robber Bars" to attract paint and reduce over-spray on the backside of the plastic part during the painting process (generating squeak issues). The bars on the backside of the racks attract the paint of the electrostatic paint line and help to prevent over-spray, reducing VOCs due to less use of paint and eliminating the need for the manual masking process. This results in a cost save of $.24 per vehicle and can be translated to all electrostatic paint lines for plastic components.

OEM/Vehicle
Ford Motor Company
2018 Ford Fusion
System Supplier
Flex-N-Gate



For More Information See: http://www.plastics-car.com/current_projects

Torsional Welding of PDC Sensors to Thin Wall Fascia


This is the first application of torsional welding (spin & ultrasonic welding combined) on automotive fascias. It allows welding of PDC brackets without localized thickening of wall stock on 2.5 mm, thin wall, molded fascias. An adjustable TPO material with high melt flow, high stiffness/ impact allowed for less material to be used resulting in a 10% reduction in mass for a 7% weight savings with $122,000 direct cost savings in three years. Cycle times were improved and there was no weld read through resulting in a quality appearance. Future applications or this process include fascia support brackets, fog brackets and more.

OEM/Vehicle
Volkswagon AG
2018 Skoda Octavia
System Supplier
Magna Exteriors
Material Processor
   Magna Bohemia Liberec
Material Supplier
SABIC
Resin
Sabic 8650 TPO
Tooling/Equipment Supplier
Changzhou Huawei Mold Co., Ltd.

For More Information See: http://www.plastics-car.com/roadmap

Integrated Sliding Armrest and Hinge Assembly


Additional console stowage volume with a lid held open to any position (like a laptop screen) is achieved with this single Injection molded upper bin and lid inner using a torque insert to create hinge for the armrest. It includes Integrated attachments for a sliding armrest that is interchangeable with a fixed armrest. Using a robotic arm, the torque insert hinge is placed into the cavity of the mold and over-molded with 30% glass-filled nylon 6. Upon mold close, the seal off around the hinge allows for the upper leaf and lower bin to be independently injected at the same time (using sequential valve gating), producing 2 complete assemblies in one press cycle. This eliminates the need for metal hinge systems saving $4.50 and 2 lbs weight per unit

OEM/Vehicle
Ford Motor Company
2017 Ford EcoSport
System Supplier
Faurecia Interior Systems
Material Processor
   M & N Plastics
Material Supplier
BASF Corporation
Resin
Ultramid B3EG6 30% GF PA 6
Tooling/Equipment Supplier
M & N Plastics

For More Information See: http://www.plastics-car.com/futuredesign

Two Shot Interior Decoration Bezel


This unique 3-D decorative effect was achieved with 2K 'reverse' injection molding (1st shot tinted PC) with overmolding of grained surface with 2nd shot (self colored pigmented ABS). This is the first time this process was used to achieve the 3-D visual effect (color and texture) for a part of this size and geometry. A 30% cost save was achieved vs IMD/IML/high gloss painting and there was a 20% scrap reduction vs conventional 2-layer high gloss piano black appearance.

OEM/Vehicle
Ford Motor Company
2018 Ford Fiesta
System Supplier
Faurecia Interior Systems
Material Processor
   Faurecia Interior Systems
Material Supplier
Lotte Advanced Materials
Resin
INFINO LT1220 PC
Starex LX0760 ABS
Tooling/Equipment Supplier
JP Grosfilley SAS

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Latest-Trends?css=print

Winged Spring Clip with 4 Way Locator


Metal clips and springs were eliminated by designing an in-molded W shaped plastic clip with a 4-way locator providing efficient attachment per requirements and eliminating additional costs for fasteners and assembly. The plastic part comes out of the tool with the clips molded in. The patented winged spring clip design locates, locks and retains in a single snapping action. A cost save of $0.17 per clip/$2.19 per vehicle resulting in $250K per year; and a 10% weight saving is achieved.


OEM/Vehicle
Ford Motor Company
2018 Expedition/Navigator
System Supplier
Magna Seating
Material Processor
   Royal Technologies
Material Supplier
Advanced Composites
Resin
ADX 5017 TPO
Tooling/Equipment Supplier
Tri Tech Tooling, Inc.

For More Information See: http://www.plastics-car.com/lightvehiclereport

Part via Preform (PVP) Assembly Carrier


Part via Preform (PvP) technology enables economical production of carbon fiber reinforced plastic (CFRP) automotive parts. The carbon fiber has been binder-modified to be sprayed into near-net shape preforms without intermediate textile processing resulting in a 30% cost save. High fiber volume content (50% Vf), delivers high mechanical properties. The process can create complex shapes with homogenous material and can be combined with aligned fiber placement (AFP) for part reinforcement. Resin injection of PvP preforms works with high pressure resin transfer molding (HP-RTM) including an inmold coating step to provide for easy surface painting. The binder on the carbon fiber can be activated, allowing for greater design freedom, and ability to assemble preforms and achieve local thickness variations to exacting specs.


OEM/Vehicle
Volkswagon AG
2016 Porsche GT3 Cup II
System Supplier
Toho Tenax
Material Processor
   Toho Tenax
Resin
Epoxy


For More Information See: http://www.plastics-car.com/plasticfueltanks

Engine Coolant Control Valve


This unique product design allows good fluid control and low coolant leakage at the seals on the valve moving components. Dimensional control is provided through innovative molding and assembly processes with the combination of PPA and PPS materials. A 1 lb weight savings and 20% cost savings is achieved, compared to a metal part. An approximate 2% increase in fuel efficiency and reduced emissions result in a reduced carbon foot print.

OEM/Vehicle
FCA US LLC
2016 GME-T4 (Alfa Romeo - Guilia/
Stelvio)
System Supplier
ITW Powertrain Components
Material Processor
   ITW Powertrain Components
Material Supplier
Dupont Automotive
Resin
Zytel HTN 51G35HSLR BK420 PPA


For More Information See: http://www.plastics-car.com/compositefueltanks

Transmission Baffle



Unique part geometry and CFD (Computational Fluid Dynamics) studies led to the design of this new baffle for injection molding enabling seal elements and fluid flow passages for improved transmission performance - not possible before in a stamped metal component. Transmission efficiency was improved by 8% resulting
in up to 0.5 mpg economy. A reduction of 50% in weight and 40% in cost ($1 per transmission) was gained compared to a metal part with molded seal elements. The TPE material is recyclable reducing its carbon footprint.

OEM/Vehicle
Ford Motor Company
2018 Ford Focus
System Supplier
Ford
Material Processor
   Toledo Molding and Die
Material Supplier
Dupont Automotive
Resin
Hytrel 7246 TPE
Tooling/Equipment Supplier
Toledo Molding and Die

For More Information See: http://www.plastics-car.com/s_plasticscar/fuel_economy/Default.html

Carbon Fiber Torque Tube


This CFRP torque tube is unique in its performance, complexity, dimensions and manufacturing process and has been developed for extreme lightweight construction and vehicle performance. Extreme lightweight construction (-40%), highest stiffness and NVH performance, high safety reserves, temperature load up to 200 degrees, and monolithic implementation of the complex structure in a one-shot production step. It was produced with a new process (first time in auto industry) that is a combination of resin transfer molding and a process from blow molding flexible tubes. The component was inflated in the interior of the tool by vacuum and overpressure. The injection from the resin takes place from the outside.

OEM/Vehicle
Mercedes-Benz GmbH
2017 Mercedes AMG GT R
System Supplier
ACE Advanced Composite Engineering
GmbH
Material Processor
   ACE Advanced Composite Engineering
GmbH
Material Supplier
Huntsman
Resin
Huntsman 8625 epoxy


For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains?css=print